Docstoc

Polypropylene Resin Composition - Patent 6689841

Document Sample
Polypropylene Resin Composition - Patent 6689841 Powered By Docstoc
					


United States Patent: 6689841


































 
( 1 of 1 )



	United States Patent 
	6,689,841



 Jung
,   et al.

 
February 10, 2004




 Polypropylene resin composition



Abstract

The present invention relates to a polypropylene resin composition and more
     particularly, to the polypropylene resin composition comprising: (A) a
     propylene polymer comprising a propylene-ethylene copolymer having a
     certain limit viscosity alone and/or a propylene homopolymer having a
     certain pentad fraction (% mmmm); (B) an ethylene-.alpha.-olefin copolymer
     rubber comprising ethylene-propylene copolymer rubber and
     ethylene-.alpha.-olefin copolymer; (C) a styrene copolymer rubber; (D) a
     polypropylene modified with polar group-containing resin or a polyolefin
     polyol; and (E) an inorganic filler.


 
Inventors: 
 Jung; Soon-Joon (Kyoungki-do, KR), Choi; Jae-Rim (Daejon, KR), Park; Bong-Hyun (Kyoungki-do, KR) 
 Assignee:


Hyundai Motor Company
 (Seoul, 
KR)


LG Caltex Co., Ltd.
 (Seoul, 
KR)





Appl. No.:
                    
 10/005,730
  
Filed:
                      
  November 6, 2001


Foreign Application Priority Data   
 

Mar 08, 2001
[KR]
2001-12075



 



  
Current U.S. Class:
  525/240  ; 525/241; 525/423; 525/424; 525/426; 525/427; 525/445; 525/451; 525/70; 525/88; 525/98; 525/99
  
Current International Class: 
  C08L 23/00&nbsp(20060101); C08L 23/10&nbsp(20060101); C08L 23/16&nbsp(20060101); C08L 51/00&nbsp(20060101); C08L 53/00&nbsp(20060101); C08L 51/06&nbsp(20060101); C08L 023/00&nbsp()
  
Field of Search: 
  
  












 525/260,241,88,98,99,70,78 524/451,424,426,427,445,423
  

References Cited  [Referenced By]
U.S. Patent Documents
 
 
 
5283267
February 1994
Nishio et al.

5324771
June 1994
Suehiro et al.

5462987
October 1995
Shinonaga et al.

5629371
May 1997
Kitagawa et al.

6147152
November 2000
Kanome et al.

6441081
August 2002
Sadatoshi et al.

2002/0013417
January 2002
Jung et al.

2002/0193489
December 2002
Jung et al.



   Primary Examiner:  Wu; David W.


  Assistant Examiner:  Lee; Rip A


  Attorney, Agent or Firm: Christie, Parker & Hale, LLP



Claims  

What is claimed is:

1.  A polypropylene resin composition comprising the following components (A), (B), (C), (D), and (E): (A) 30 to 70 wt. % of a propylene polymer comprising 0 to 30 wt. % of a
propylene homopolymer and 70 to 100 wt. % of a propylene-ethylene copolymer;  (B) 10 to 30 wt. % of an ethylene .alpha.-olefin copolymer rubber comprising 60 to 95 wt. % of an ethylene-propylene copolymer rubber and 5 to 40 wt. % of an ethylene
.alpha.-olefin copolymer;  (C) 1 to 10 wt. % of a styrene-based copolymer rubber comprising 10 to 50 wt. % of a polymer block of styrene or its derivative, 50 to 90 wt. % of a polymer block of at least one selected from the group consisting of ethylene,
isoprene, butylene, butadiene, and propylene;  (D) 1 to 7wt.  % of a polar-group containing resin comprising a modified polypropylene grafted to a graft ratio of 0.5 to 6.0 wt. % a polyolefin polyol, or a mixture thereof;  and (E) 10 to 40 wt. % of an
inorganic filler selected from the group consisting from talc, barium sulfate, potassium carbonate, and wollastonite.


2.  The polypropylene resin composition according to claim 1, wherein said propylene homopolymer has a pentad fraction (% mmmm) higher than 96% measured with .sup.13 C NMR and a limit viscosity of 0.7-2.5 dl/g and further wherein said
propylene-ethylene copolymer has a limit viscosity of 0.7-2.5 dl/g and an ethylene content of 3-20 wt. %.


3.  The polypropylene resin composition according to claim 1, wherein said ethylene-propylene copolymer rubber has a Mooney viscosity [.eta.].sub.ML1+4 (125.degree.  C.) of 50-80 dl/g and a propylene content of 20-80 wt. %.


4.  The polypropylene resin composition according to claim 1, wherein said ethylene-.alpha.-olefin copolymer has a melt index of 0.5-10 g/10 min and an .alpha.-olefin content of 12-45 wt. %.


5.  The polypropylene resin composition according to claim 1, wherein said styrene copolymer rubber is linear or nonlinear and has more than 97% of unsaturated bonds.


6.  The polypropylene resin composition according to claim 1, wherein said modified polypropylene is a polypropylene grafted with dimethylol-p-octylphenol, an unsaturated carbonic acid or a derivative thereof where the unsaturated carbonic acid
is selected from the group consisting of maleic acid, acrylic acid, methacrylic acid, maleic anhydride and mixtures thereof.


7.  The polypropylene resin composition according to claim 1, wherein said polyolefin polyol has polar hydroxyl (--OH) groups bonded at both ends of the saturated hydrocarbon backbone having 150 to 200 carbon atoms, a viscosity of 10 to 16 poise
(100.degree.  C.) and a hydroxyl value of 20 to 80 KOH mg/g.


8.  The polypropylene resin composition according to claim 1, wherein said inorganic filler has an average particle size of 0.5 to 7 .mu.m.


9.  The polypropylene resin composition according to claim 1, wherein the melt index of the entire composition is in the range of 3-40 g/10 min.


10.  An interior automotive article which is molded from the polypropylene resin composition of claim 1 by an injection molding.  Description  

CROSS-REFERENCE TO RELATED APPLICATION


This application claims priority of Korea patent Application No. 2001-12078, filed on Mar.  8, 2001.


FIELD OF THE INVENTION


The present invention relates to a polypropylene resin composition and more particularly, to the polypropylene resin composition comprising: (A) a propylene polymer comprising a propylene-ethylene copolymer having a certain limit viscosity alone
and/or a propylene homopolymer having a certain pentad fraction (% mmmm); (B) an ethylene-.alpha.-olefin copolymer rubber comprising ethylene-propylene copolymer rubber and ethylene-.alpha.-olefin copolymer; (C) a styrene copolymer rubber; (D) a
polypropylene modified with polar group-containing resin or a polyolefin polyol; and (E) an inorganic filler.  The polypropylene resin composition provides superior in rigidity, scratch resistance, gloss, adhesion to paint to the conventional
polypropylene resin compositions and further provides excellent laser scoring characteristics and improved impact strength at a low temperature thus, being useful for interior automotive parts such as instrument panels, especially an instrument panel
integrally enclosing an air bag.


BACKGROUND OF THE INVENTION


Polypropylene resins have been extensively used in exterior automotive parts including automotive bumpers and interior automotive parts including instrument panels and pillars, because they are excellent in flowability, impact strength, chemical
resistance, and low-cost and have low specific gravity.  However, in a case of interior automotive parts such as instrument panels, especially an instrument panel integrally enclosing air bag, an air bag is mounted within the instrument panel after the
portion where the air bag is stowed is cut and then concealed that portion thus, resulting in vexatious complication and poor appearance.  On the other hand, when an air bag is installed integrally within the instrument panel to remove such
complications, there is a possibility of no opening of the air bag in an accident.  Therefore, it is required to preweaken components overlaying an air bag enclosed within the instrument panel by scoring with the use of laser beam to be properly deployed
in emergency.  Accordingly, the instrument panel integrally overlying an air bag is expected to have excellent physical properties and adhesion to the paint and additionally stand laser scoring for the air bag to properly open in emergency.  And further,
it is required to exhibit excellent impact strength at a low temperature not to form broken pieces thereof when the air bag inflates.


There have been development of polypropylene resin compositions for interior automotive parts such as an instrument panel which provide good rigidity and physical properties and thus suitable for direct painting without a pretreatment but there
is no development of polypropylene resin composition suitable for an instrument panel integrally enclosing an air bag.  The inventors of the present invention have disclosed the polypropylene resin composition suitable for the instrument panel having
excellent physical properties and adhesion to paint in U.S.  patent application Ser.  No. 09/749,698.  However, the polypropylene resin composition disclosed in U.S.  patent application Ser.  No. 09/749,698 has excellent rigidity, physical properties and
adhesion but it becomes dangerous for broken pieces formed with the inflation of an air bag due to lowered impact strength at a low temperature after post-treatment with laser beam.


Therefore, it is highly demanded to develop a polypropylene resin composition having excellent physical properties, adhesion to paints and additionally superior low-temperature impact strength required for an air bag deployment opening in an
automotive industry.


SUMMARY OF THE INVENTION


An object of the present invention is to provide a polypropylene resin composition having excellent physical properties such as rigidity, scratch resistance, gloss, and adhesion to paints, laser scoring characteristics and highly reinforced
low-temperature impact strength by comprising: a propylene polymer selected from the group consisting of a propylene-ethylene copolymer, and/or a propylene homopolymer; an ethylene .alpha.-olefin copolymer rubber comprising an ethylene-propylene
copolymer rubber and ethylene-.alpha.-olefin copolymer; a styrene copolymer rubber, a polar group-containing resin, and an inorganic filler.


DETAILED DESCRIPTION OF THE INVENTION


The present invention is characterized by a polypropylene resin composition comprising; (A) 30 to 70 wt. % of a propylene polymer comprising 0 to 30 wt. % of propylene homopolymer and 70 to 100 wt. % of propylene-ethylene copolymer; (B) 10 to 30
wt. % of an ethylene .alpha.-olefin copolymer rubber comprising 60 to 95 wt. % of ethylene-propylene copolymer rubber and 5 to 40 wt. % of ethylene .alpha.-olefin copolymer; (C) 1 to 10 wt. % of a styrene copolymer rubber comprising 10 to 50 wt. % of
polymer blocks of styrene or its derivative, 50 to 90 wt. % of polymer blocks copolymerized with at least one selected from ethylene, isoprene, butylene, butadiene, and propylene; (D) 1 to 7 wt. % of polar-group containing resin comprising a modified
polypropylene grafted to 0.5 to 6.0 wt. % of graft ratio, a polyolefin polyol, or mixture thereof; and (E) 10 to 40 wt. % of an inorganic filler selected from the group consisting from talc, barium sulfate, potassium carbonate, and wollastonite.


The polypropylene resin composition of the present invention provides an interior automotive material suitable for an instrument panel integrally enclosing air bag with an injection molding.  The instrument panel integrally enclosing an air bag
with excellent laser scoring property and low-temperature impact strength is prepared from the molded article by coating without primer treatment and mounting an air bag.


Hereunder is given the detailed description of each component comprising the polypropylene resin composition of the present invention.


(A) Propylene Polymer


A propylene copolymer of the present invention is a crystalline polymer comprising a propylene-ethylene copolymer containing ethylenes and/or a propylene homopolymer.


Said propylene homopolymer has higher than 96% of pentad fraction (% mmmm) measured with .sup.13 C-NMR, preferably higher than 96.5%, and more preferably higher than 97%.  If the pentad fraction is lower than 96%, the rigidity and heat resistance
of the polypropylene resin composition become inferior.  Also, the limit viscosity [.eta.] of said propylene polymer of the present invention measured in 135.degree.  C. of decalin is in the range of 0.7 to 2.5 dl/g, preferably in the range of 0.85 to
2.2 dl/g, and more preferably in the range of 0.9 to 2.0 dl/g. If the limit viscosity [.eta.] is lower than 0.7 dl/g, the impact strength of the formed polypropylene resin composition worsens, and if it exceeds 2.5 dl/g, the flowability becomes poor, so
that the quality of the finally formed product worsens and the working condition becomes poor.


Said propylene-ethylene copolymer includes 3 to 20%, and preferably 5 to 15% of an ethylene content.  The limit viscosity [.eta.] of propylene-ethylene block copolymer of the present invention measured in 135.degree.  C. of decalin is in the
range of 3.0 to 6.0 dl/g, preferably higher than 3.5 dl/g, and more preferably higher than 4.0 dl/g.


For a well-balanced properties of impact strength and fluidity, the composition of the propylene homopolymer and the propylene-ethylene copolymer is recommended to be in the range of 0 to 30:70 to 100 wt. %, and more preferably in the range of 0
to 20:80 to 100 wt. %. While the propylene homopolymer provides superior rigidity and heat resistance, it has poor impact strength.  On the other hand, the propylene-ethylene copolymer provides improved impact strength, especially at a low temperature
but it has poor formability, rigidity and heat resistance.  Therefore, they can complement each other when mixed together.


The content of the propylene copolymer to the entire polypropylene resin is recommended to be in the range of 30 to 70 wt. %, more preferably in the range of 45 to 65 wt. %. If it is used more then 70 wt. %, the impact strength becomes impaired. 
On the other hand if it is used lower than 30 wt. %, the formability becomes poor.


(B) Ethylene-.alpha.-Olefin Copolymer Rubber


An ethylene-.alpha.-olefin copolymer rubber (B) of the present invention comprises an ethylene-propylene copolymer rubber and ethylene-.alpha.-olefin copolymer and is added to increase the impact strength by providing elasticity to the entire
polypropylene resin composition.


The Mooney viscosity [.eta.].sub.ML1+4 (125.degree.  C.) of the ethylene-propylene copolymer rubber (EPR) is in the range of 50 to 80 dl/g, preferably in the range of 55 to 70 dl/g. If the Mooney viscosity is higher than 80 dl/g, an appearance is
inferior due to poor dispersion and the mechanical properties also become worsen.  On the other hand, if it is less than 20 dl/g, the impact strength is lowered.  The ethylene-propylene copolymer rubber (EPR) includes 20 to 80 wt. % of a propylene
content, preferably 40 to 80 wt. %. If the content of propylene is lower than 20 wt. %, the impact strength worsens, and if it exceeds 80 wt. %, the rigidity worsens.


In particular, the ethylene-.alpha.-olefin copolymer of the present invention, is ethylene 1-butene (EBM) or ethylene 1-octene copolymer (EOM) and it is preferred to contain 12-45 wt. % of an .alpha.-olefin content.  Said EBM having 12-45 wt. %
of a butene content, preferably 15-20 wt. % and 0.5-10 g/10 min of a melt index, preferably 1-5 g/10 min, is preused.  Said EOM having 15-45 wt. % of an octene content, preferably 25-35 wt. %, 1-50 dl/g of limit viscosity [.eta.].sub.ML1+4 (121.degree. 
C.), preferably 1.5-35 dl/g, and 0.86-0.91 g/cm.sup.3 of a density, preferably 0.87-0.90 g/cm.sup.3, is used.


Ethylene-propylene copolymer rubber (EPR) and ethylene .alpha.-olefin copolymer are mixed in the range of 60 to 95:40 to 20 wt. %, preferably in the range of 80 to 85:20 to 15 wt. % for the good of impact strength and rigidity balance.  If
ethylene-propylene copolymer rubber (EPR) is used solely, the rigidity worsens; and if .alpha.-olefin copolymer is used solely, the impact resistance worsens.


The content of ethylene-.alpha.-olefin copolymer rubber to the entire polypropylene polymer is recommended to be in the range of 10 to 30 wt. %, preferably in the range of 15 to 25 wt. %. If the said content is below 10 wt. %, the rigidity and
formability worsen; and if it exceeds 30 wt. %, the impact strength worsens.


(C) Styrene Copolymer Rubber


A styrene copolymer rubber of the present invention comprises a polymer block of styrene or its derivate; and a polymer block of at least one selected from ethylene, isoprene, butadiene, and propylene to improve the impact strength without
reducing the rigidity.


The copolymer rubber used in the present invention has higher than 97% of unsaturated bonds and an "a-b-a" linear type or non-linear type, wherein "a" block is formed from styrene or its derivative, "b" block is formed from at least one selected
from ethylene, isoprene, butadiene, and propylene.  "a" Block is used to enhance rigidity, gloss, tensile strength and hardness of the resin composition and "b" block is used to improve compatibility with the olefin resin composition.  "a" Block is used
in the range of 10 to 50 wt. %. If a content of "a" block is less than 10 wt. %, the rigidity and hardness are inferior.  On the other hand, if it is more than 50 wt. %, the compatibility to olefin resin composition becomes poor, resulting in poor impact
strength.


A content of styrene copolymer rubber to the entire polypropylene polymer is recommended to be in the range of 1 to 10 wt. %, preferably in the range of 1.5 to 7 wt. %. If the said content is higher than 10 wt. %, the gloss worsen; and if it is
less than 1 wt. %, the elongation, etc is impaired.


(D) Polar Group-Containing Resin


A polar group-containing resin used in the present invention is a modified polypropylene, a polyolefin polyol, or a mixture thereof.


The modified polypropylene is a polypropylene copolymer grafted with dimethylol-p-octylphenol, an unsaturated carbonic acid or a derivative thereof, wherein examples of the unsaturated carbonic acid include maleic acid, acrylic acid, methacrylic
acid, anhydrous maleic acid, and mixtures thereof.  Here, a graft ratio is recommended to be 0.5 wt. % or higher, preferably 1.5wt.  % or higher.  If the graft ratio is lower than 0.5wt.  %, it can be scraped by external impact due to poor adhesion to
paint.


The polyolefin polyol of the present invention has polar hydroxyl (--OH) groups bonded at both ends of the saturated carbohydrate backbone having 150 to 200 carbon atoms.  The polyolefin polyol is a low-molecular polymer with 10 to 16 poise
(100.degree.  C.) of viscosity, 20 to 80 KOH mg/g of hydroxyl value.  If the hydroxyl value of polyolefin polyol is lower than 20 KOH mg/g, the adhesion to paint becomes impaired.  Otherwise if it exceeds 80 KOH mg/g, the adhesion to paint improves but
the rigidity and impact strength worsen.


The modified polypropylene and polyolefin polyol according to the present invention can be used solely or mixed together.  When used solely, the modified polypropylene is recommended to be in the range of 1 to 10 wt. %, preferably in the range of
1 to 5 wt. % to the entire polypropylene composition; and the polyolefin polyol is recommended to be in the range of 1 to 5 wt. %, preferably in the range of 1 to 3 wt. % to the entire polypropylene composition.  When the two components are mixed
together, the content of the mixed resin is recommended to be in the range of 1 to 7 wt. % to the entire polypropylene resin composition.  If the content exceeds 7 wt. %, the impact property and rigidity may worsen.


(E) Inorganic Filler


An inorganic filler having an average particle size of 0.5 to 7 .mu.m of the present invention is selected from the group consisting of talc, barium sulfate, calcium carbonate and wollastonite.  Especially, talc with smaller average particle size
than 7 .mu.m is preferable in view of dispersion and other properties.


This inorganic filler is added in the range of 10 to 40 wt. % to the entire polypropylene resin.  If the content is lower than 10 wt. %, the rigidity and heat resistance worsen, and if it exceeds 40 wt. %, the impact strength worsens.


Other additives, used by one having ordinary skill in the art, such as an anti-oxidant, a neutralizer, an anti-static agent, and a nucleating agent may be arbitrarily incorporated in an appropriate content not to obstruct the above-mentioned
object of the present invention.  Examples of the anti-oxidant are phenols, phosphates, and thiodipropionate synergists and examples of the neutralizer are calcium stearate and zinc oxide.


The polypropylene resin composition comprises the components (A) to (E) in the respective prescribed amount and if desired, an additional additive has a melt index of 3 to 40 g/10 min. When it is lower than 3 g/10 min, processability may be
degraded and the flow mark of the product may occur.  On the other hand, when it is higher than 40 g/10 min, the physical properties such as strength, rigidity, and impact strength become poor.


The method for preparing the polypropylene resin composition of the present invention is not limited to any special method.  For example, components (A), (B), (C), (D), and (E) of the polypropylene resin composition according to the present
invention can be prepared by a conventional mechanical mixing method.  To be specific, general melt mixing machines such as Bambury mixer, single-screw extruder, twin-screw extruder and multi-screw extruder can be employed.  Here, the mixing temperature
is recommended to be in the range of 170 to 240.degree.  C.


The resin composition of the present invention can be subjected to the production by any of various molding techniques including extrusion, blow molding, injection molding, and sheet molding.  Of these molding techniques, injection molding is
preferably used.


The formed interior automotive parts prepared from the polypropylene resin composition of the present invention can be directly painted using modified acryl paint or urethane paint without the pretreatment.  And then it is scored using the laser
beam around an air bag.  Since a particular infrared frequency (943 cm.sup.-1) is used to have an even thickness after scoring, the resin composition has a high penetration to the used infrared frequency.  If the penetration is low, it becomes impossible
to control the thickness, resulting in uneven thickness, no opening of the air bag, and the formation of broken pieces if it is opened.  Therefore, the test for proper opening of the air bag is performed.


Hereunder is given a more detailed description of the present invention using examples.  However, it should not be construed as limiting the scope of this invention. 

EXAMPLE AND COMPARATIVE EXAMPLE


The polypropylene resin composition comprising polypropylene resin (A), (B), (C), (D) and (E) with the amount listed in tables 1-5 was mixed with the mixing ratio listed in table 6 by means of Henschel mixer (trade name).  The resulting mixture
was melt-kneaded with twin-screw extruder having a diameter of 45 mm .PHI.  and then pelletized.


(A) Propylene Copolymer


Physical properties of the used propylene copolymer are summarized in Table 1.  The isotatic pentad fraction of the propylene homopolymer measured with .sup.13 C NMR was 96.8% mmmm and intrinsic viscosities of the propylene homopolymer and
ethylene-propylene copolymer were determined in 135.degree.  C. of decalin.  Limit viscosity of the solution was measured with Ubbeholde viscometer.


 TABLE 1  Intrinsic E.sub.p.sup.4)  MI.sup.1) viscosity E.sub.c.sup.2) R.sub.c.sup.3)  ([.eta.],  Category (g/10 min) ([.eta.], dl/g) (wt. %) (wt. %) dl/g)  Propylene PP-1.sup.5) 8 1.9 -- -- --  homopolymer PP-2.sup.5) 14.5 1.3 -- -- -- 
Propylene- PP-3.sup.5) 60 -- 60 15 4.3  ethylene PP-4.sup.5) 10 -- 41 11 4.7  copolymer  .sup.1) MI: Melt index measured with ASTM D1238 (230.degree. C./2.16 kg)  .sup.2) E.sub.c : Ethylene Content determined with FT-IR  .sup.3) R.sub.c : Xylene Extract
Content  .sup.4) E.sub.p : Limit Viscosity  .sup.5) PP-1, PP-2, PP-3, PP-4: Products manufactured from LG-Caltex Oil  Corporation


(B) Ethylene-Propylene Copolymer Rubber


Physical properties of the used ethylene-propylene copolymer rubber and ethylene-.alpha.-olefin copolymer are summarized in Table 2.


TABLE 2  Mooney viscosity.sup.1)  Category (ML.sub.1+4, 50 dl/g) C.sub.c.sup.2) (wt. %)  Ethylene- EPR-1.sup.3) 65 53.5  propylene EPR-2.sup.4) 42 68  copolymer EPR-3.sup.3) 13 69  Ethylene-.alpha.- EOM-1.sup.5) 23 24  olefin EOM-2.sup.5) 8 24 
copolymer  .sup.1) Mooney viscosity is measured with ASTM D1646  .sup.2) C.sub.c : a comonomer content determined with FT-IR  .sup.3) EPR-1 & DPR-3 are manufactured from Kumho EP Co., Ltd.  .sup.4) EPR-2 is manufactured from Misui Chemical Co.  .sup.5)
EOM-1 & EOM-2 are manufactured from Dow-Dupont Chemical Co.


(C) Styrene Copolymer Rubber


Physical properties of the used styrene copolymer rubber are summarized in Table 3.


 TABLE 3  Content of styrene Structure of  Category Type of copolymer (wt. %) polymer chain  St-1 Ethylene-butyrene 13 Linear  St-2 butadiene 31 Linear  1) St-1 & St-2: products manufactured from Shell


(D) Polar Group-Containing Resin


Physical properties of the used polar group-containing resin are summarized in Table 4.


 TABLE 4  Hydroxy value Type of polar  Category F.sub.c.sup.1) (wt. %) (KOH mg/g) group  MPP.sup.2) 1.5 -- -COOH  Polyol -- 45 -OH  .sup.1) F.sub.c : A content of polar group  .sup.2) MMP: Maleic anhydride modified polypropylene manufactured from LG-Caltex Oil Corporation  3) Polyol: Polytail-H manufactured from Misui Chemical Co.


(E) Inorganic Filler


Physical properties of the used inorganic filler are summarized in Table 5.


 TABLE 5  Category Average particle size.sup.3) (.mu.m)  T-1.sup.1) 2.9  T-2.sup.2) 7.6  .sup.1) T-1: Talc manufactured from KOCH Co.  .sup.2) T-2: talc manufactured from KOCH Co.  .sup.3) Average particle size is measured with laser
sedimentation method


 TABLE 6  Example Comparative Example  Content (wt. %) 1 2 3 4 1 2 3 4  (A) PP-1 5 0 10 0 5 5 5 0  PP-2 0 10 0 0 0 0 0 0  PP-3 0 0 0 10 0 0 0 0  PP-4 53 40 40 50 55 49 40 15  (B) EPR-1 5 19 13 13 0 0 17 12  EPR-2 5 0 0 0 10 15 0 0  EPR-3 0 0 0 0
5 0 0 0  EOM-1 7 5 0 2 0 0 0 0  EOM-2 0 0 10 0 0 5 3 10  (C) St-1 3 3 0 3 3 3 12 3  St-2 0 0 5 3 0 0 0 0  (D) MPP 0 3 0 0 0 0 3 0  Polyol 2 0 2 2 2 3 0 0  (E) T-1 20 20 20 17 20 0 20 20  T-2 0 0 0 0 0 20 0 0


Testing Example


Test of Physical Properties


Physical properties of the polypropylene resin composition prepared from Examples 1-4 and Comparative Examples 1-4 were tested by the following method.  The result is shown in Table 7.


[Test Method] A. Melt index (MI, g/10 min): Tested with ASTM D1238 (230.degree.  C./2.16 kg) B. Izod impact resistance (kg.multidot.cm/cm.sup.2): Tested with ASTM D256 at 23.degree.  C. and at -30.degree.  C. C. Modulus of bending elasticity
(kg/cm.sup.2): Tested with ASTM D790 D. Rockwell hardness: Tested with ASTM D785 E. Gloss: Tested with ASTM D523 using Saze/Gloss meter of BYK-Gardner F. Scratch resistance: Tested with ASTM D3363 G. Adhesion to paint: The injection molded specimen was
coated with modified acryl paint or urethane paint and dried at 80.degree.  C. for 30 min and further left at room temperature for more than 48 hrs.  The coating on the specimen a was cut at an interval of 2 mm in longitudinal and transverse directions. 
Thus, a checkered pattern of 10.times.10(=100) squares was formed on the coated layer surface, and a cellophane adhesive tape was firmly adhered to each checker pattern under a finger pressure.  Thereafter, the pressure-sensitive adhesive tape was
abruptly released.  The remaining checker patters was determined and the result thereof is summarized in Table 7.


TABLE 7  Score Remark  10 The coating film was not peeled at all  8 The coating film was little peeled which is less than 5% to the  area of a regular tetragon.  6 The coating film was peeled about 5-15% to the area of a  regular tetragon.  4 The
coating film was peeled about 15-35% to the area of a  regular tetragon.  2 The coating film was peeled about 35-65% to the area of a  regular tetragon.  0 The coating film was peeled more than 65% to the area of a  regular tetragon.  F. Laser scoring:
The surface of the sample was treated with laser beam  mined whether an absorbance at 943 cm.sup.-1 through 0.1 mm of thickness  or not (.circleincircle. for detectable and X for undetectable).  G. Air bag deployment opening: Specimen for the air bag
deployment opening  test is prepared under the condition shown in Table 8.


 TABLE 8  Category Heat aging.sup.1) Life cycle.sup.2) Virgin.sup.3)  -30.degree. C. 3 3 3  21.degree. C. 2 2 2  85.degree. C. 3 3 3  .sup.1) Heat aging: left at 107.degree. C. for 240 hrs, 21.degree. C. for 8  hrs and at the above temperatures
for 4 hrs  .sup.2) Life cycle: left at a temperature of from 85 to -30.degree. C. for  14 days and then 21.degree. C. for 8 hrs  .sup.3) Virgin: left 21.degree. C. for 8 hrs  *Criterion for judging: depending on the formation of broken pieces under  the
three conditions when the air bag opens by indicating .circleincircle.  for no formation and X for formation.


 TABLE 9  Example Comparative Example  Content (wt. %) 1 2 3 4 1 2 3  4  (A) PP-1 5 0 10 0 5 5 5  0  PP-2 0 10 0 0 0 0 0  0  PP-3 0 0 0 10 0 0 0  0  PP-4 53 40 40 50 55 49 40  15  (B) EPR-1 5 19 13 13 0 0 17  12  EPR-2 5 0 0 0 10 15 0  0  EPR-3 0
0 0 0 5 0 0  0  EOM-1 7 5 0 2 0 0 0  0  EOM-2 0 0 10 0 0 5 3  10  (C) St-1 3 3 0 3 3 3 12  3  St-2 0 0 5 3 0 0 0  0  (D) MPP 0 3 0 0 0 0 3  0  Polyol 2 0 2 2 2 3 0  0  (E) T-1 20 20 20 17 20 0 20  20  T-2 0 0 0 0 0 20 0  0  MI (g/10 min) 6.1 6.0 7.3 5.6
7.3 7.6 7.3  7.8  Izod 23.degree. C. 42 45 42 45 38 35  46 45  impact -30.degree. C. 6.5 7.0 6.8 7.1 4.8 4.3  7.4 6.5  resistance  Modulus of 21000 21600 21000 20000 21000 20000 21000  20000  bending elasticity  Rockwell 61 65 65 50 70 60 60  50 
hardness  Gloss 23 24 28 25 26 31 33  24  Scratch resistance 4B 3B 3B 4B 4B 4B 4B  5B  Coating 10/10 10/10 10/10 10/10 10/10 10/10 10/10  2/10  adhesion*  Laser scoring .circleincircle. .circleincircle. .circleincircle.  .circleincircle. .circleincircle.
.circleincircle. X  .circleincircle.  property  Air bag .circleincircle. .circleincircle. .circleincircle.  .circleincircle. X X X .circleincircle.  deployment  opening  *Coating adhesion: modified acryl/urethane paint


As shown in Table 9, the resin composition of Examples 1-4 provided excellent impact strength, hardness, coating adhesion which does not require any pretreatment, laser scoring property and air bag deployment opening.  However, when the
ethylene-propylene rubber having low viscosity was used alone in Comparative Examples 1, it was dangerous for the broken pieces formed with the air bag opening.  Further, the impact strength is impaired with use of talc having a large average particle
size in Comparative Example 2.  The physical properties and laser scoring properties were reduced which resulted in poor impact strength during the air bag deployment opening with use of large amount of styrene copolymer rubber in Comparative Example 3. 
The coating adhesion was inferior when the polar group-containing resin was not used or used little.


As described above, the polypropylene resin composition of the present invention provides a well-balanced combination of the properties such as rigidity and impact strength, and excellent laser scoring property and is capable of painting directly
without the pretreatment to be suitable for interior automotive parts, especially an instrument panel integrally enclosing an air bag.


* * * * *























				
DOCUMENT INFO
Description: This application claims priority of Korea patent Application No. 2001-12078, filed on Mar. 8, 2001.FIELD OF THE INVENTIONThe present invention relates to a polypropylene resin composition and more particularly, to the polypropylene resin composition comprising: (A) a propylene polymer comprising a propylene-ethylene copolymer having a certain limit viscosity aloneand/or a propylene homopolymer having a certain pentad fraction (% mmmm); (B) an ethylene-.alpha.-olefin copolymer rubber comprising ethylene-propylene copolymer rubber and ethylene-.alpha.-olefin copolymer; (C) a styrene copolymer rubber; (D) apolypropylene modified with polar group-containing resin or a polyolefin polyol; and (E) an inorganic filler. The polypropylene resin composition provides superior in rigidity, scratch resistance, gloss, adhesion to paint to the conventionalpolypropylene resin compositions and further provides excellent laser scoring characteristics and improved impact strength at a low temperature thus, being useful for interior automotive parts such as instrument panels, especially an instrument panelintegrally enclosing an air bag.BACKGROUND OF THE INVENTIONPolypropylene resins have been extensively used in exterior automotive parts including automotive bumpers and interior automotive parts including instrument panels and pillars, because they are excellent in flowability, impact strength, chemicalresistance, and low-cost and have low specific gravity. However, in a case of interior automotive parts such as instrument panels, especially an instrument panel integrally enclosing air bag, an air bag is mounted within the instrument panel after theportion where the air bag is stowed is cut and then concealed that portion thus, resulting in vexatious complication and poor appearance. On the other hand, when an air bag is installed integrally within the instrument panel to remove suchcomplications, there is a possibility of no opening of the air bag in an accident. Therefore, it is